Wire harnesses operate akin to the circulatory system in humans, transmitting messages, delivering energy, and collecting and distributing data that describes the system’s external environment. Despite their critical role in the overall performance of electrical devices, wiring harnesses and cable assemblies are often overlooked and neglected in many designs.
A wire harness refers to an assembly of wires that transmits power and signals within an appliance. In 1980, wiring safety became a significant concern due to a surge in accidents, particularly in the aviation industry, which was attributed to the degradation of airplane electrical wiring systems. This prompted a thorough investigation into the wiring quality and assembly practices of various companies.
The conclusion was that stricter regulation and wire harness inspection were necessary to ensure the reliable and efficient application of wire harnesses. Before delving deeper into wiring harness inspection, let’s first understand the primary causes of wire harness failures.
What Are Some Common Causes of Wiring Harness Failures?
Even minor issues with a wire harness can significantly impact its application. Various factors contribute to degradation. One of the primary issues is the lack of proper maintenance, which underscores the importance of thorough cable assembly inspection conducted by professionals.
The environment in which the wire harness operates can also affect its performance. Therefore, it is crucial to ensure that each wire harness is designed to withstand the specific environmental conditions it will be exposed to.
What is Inspected During a Wiring Harness Inspection?
A wiring harness consists of various conducting wires enclosed within an insulated covering, which is handmade by highly skilled professionals and technicians. However, routine inspections of both the internal and external components of the wire harness are necessary.
During a wiring harness inspection, some key aspects to look out for include:
- Corrosion
- Dirty connections
- Loose terminal connections
- Poor electrical bonds
- Loose or broken conduit and wiring
It’s crucial to remember that a visual inspection of a wire harness alone is insufficient to determine its safety. Therefore, it’s essential to also disassemble the components for a comprehensive inspection. Bundled wires can easily hide various issues that would be difficult to detect without removing the entire wire harness system. In this context, it’s also vital to utilize various machines that aid in providing a clear and visible inspection of the wire harness.
What Are the Benefits of Conducting a Wire Harness Inspection?
A wire harness inspection provides a multitude of advantages to both the end-user and the manufacturer. It helps ensure that users can acquire a wire harness that meets the necessary requirements and standards. Additionally, the inspection aids in detecting any potential issues with the wire harness that could impact the system’s overall functionality. For the manufacturer, the cable assembly inspection ensures that they produce a wire harness that delivers optimal performance in its application.
In Conclusion
A wire harness inspection is essential to verify the reliability of a wiring harness system. Therefore, it is crucial to ensure that proper maintenance and inspection procedures are clearly outlined to provide better and more reliable services.
